Double inlet backward curved blower

ABSTRACT

A method of assembling a fan wheel includes forming a first wheel portion including a first plurality of impeller blades and a first connector, forming a second wheel portion including a second plurality of impeller blades and a second connector, affixing an end of each of the first plurality of impeller blades to a first surface of a support ring such that the first connector is affixed to the second connector, and affixing an end of each of the second plurality of impeller blades to a second surface of a support ring.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 62/623,900, filed Jan. 30, 2018, which is incorporated herein byreference in its entirety.

BACKGROUND

The disclosure relates generally to heating and cooling systems and,more particularly, to a fan wheel of a blower assembly configured foruse in such heating and cooling systems.

Heating, ventilation and air conditioning and refrigeration (HVAC & R)systems typically use a blower driven by a blower motor to supply airthrough ducts. HVAC & R systems are typically designed to provide anamount of airflow expressed as cubic feet per minute (CFM) (cubic metersper second in SI units). To meet new furnace efficiency requirements(FER) changes to existing blower wheels and motors for furnaceapplications are required. Existing blower wheels are heavy metallicassemblies that are welded or fastened together. The design oftraditional metallic blower wheel designs is typically limited by themanufacturing process used to produce such blower wheels. As a result,performance potential is limited and the drive motor size, and thecorresponding energy requirements, is increased.

BRIEF DESCRIPTION

According to an embodiment, a method of assembling a fan wheel includesforming a first wheel portion including a first plurality of impellerblades and a first connector, forming a second wheel portion including asecond plurality of impeller blades and a second connector, affixing anend of each of the first plurality of impeller blades to a first surfaceof a support ring such that the first connector is affixed to the secondconnector, and affixing an end of each of the second plurality ofimpeller blades to a second surface of a support ring.

In addition to one or more of the features described above, or as analternative, in further embodiments the first wheel portion is formedseparately from the second wheel portion.

In addition to one or more of the features described above, or as analternative, in further embodiments affixing the end of the firstplurality of impeller blades to the first surface of a support ringincludes positioning the ends of the first plurality of impeller bladesat a plurality of blade receiving areas of the first surface of thesupport ring.

In addition to one or more of the features described above, or as analternative, in further embodiments positioning the ends of the firstplurality of impeller blades at a plurality of blade receiving areas ofthe first surface includes positioning the ends of the first pluralityof impeller blades within a plurality of pockets formed in the firstsurface of the support ring.

In addition to one or more of the features described above, or as analternative, in further embodiments each of the pockets furthercomprises a first sidewall, a second sidewall, and an opening definedbetween the first sidewall and the second sidewall, and positioning theends of the first plurality of impeller blades within the plurality ofpockets further comprises installing the ends of the first plurality ofimpeller blades within the openings of the plurality of pockets.

In addition to one or more of the features described above, or as analternative, in further embodiments each of the plurality of bladereceiving areas includes a land and at least one groove adjacent theland, and positioning the ends of the first plurality of impeller bladesat a plurality of blade receiving areas of the first surface includesfurther comprises positioning the ends of the first plurality ofimpeller blades in direct contact with the plurality of lands.

In addition to one or more of the features described above, or as analternative, in further embodiments affixing an end of each of the firstplurality of impeller blades to a first surface of a support ringfurther comprises welding the ends to the plurality of blade receivingareas of the first surface of the support ring.

In addition to one or more of the features described above, or as analternative, in further embodiments welding the ends to the plurality ofblade receiving areas of the first surface of the support ring furthercomprises welding the ends of the first plurality of impeller blades tothe plurality of lands.

In addition to one or more of the features described above, or as analternative, in further embodiments welding the ends of the firstplurality of impeller blades to the plurality of lands displaces aportion of material of the lands into the at least one groove.

In addition to one or more of the features described above, or as analternative, in further embodiments coupling the first connector and thesecond connector includes welding the first connector to the secondconnector.

In addition to one or more of the features described above, or as analternative, in further embodiments at least one of the first wheelportion and the second wheel portion is formed via a plastic moldingprocess.

According to another embodiment, a fan wheel for use in a blowerassembly includes a first wheel portion including a first plurality ofimpeller blades and a second wheel portion including a second pluralityof impeller blades. A support disk is positioned near a center of thefan wheel, between the first wheel portion and the second wheel portion.The support disk couples the first wheel portion to the second wheelportion and at least one of the first wheel portion, the second wheelportion, and the support disk is formed from a plastic material.

In addition to one or more of the features described above, or as analternative, in further embodiments the first wheel portion, the secondwheel portion, and the support ring are formed separately.

In addition to one or more of the features described above, or as analternative, in further embodiments the fan wheel includes a firstplurality of blade receiving areas formed in a first surface and the fanwheel includes a second plurality of blade receiving areas formed in asecond, opposite surface.

In addition to one or more of the features described above, or as analternative, in further embodiments the first plurality of impellerblades are welded to the first plurality of blade receiving areas.

In addition to one or more of the features described above, or as analternative, in further embodiments the first plurality of impellerblades are mechanically coupled to the first plurality of bladereceiving areas.

In addition to one or more of the features described above, or as analternative, in further embodiments the first plurality of bladereceiving areas include a plurality of pockets including openingscomplementary to the first plurality of impeller blades.

In addition to one or more of the features described above, or as analternative, in further embodiments the first wheel portion furthercomprises a first connector and the second wheel portion furthercomprises a second connector and the first connector is coupled to thesecond connector.

In addition to one or more of the features described above, or as analternative, in further embodiments the first connector is welded to thesecond connector.

These and other advantages and features will become more apparent fromthe following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWING

The subject matter, which is regarded as the disclosure, is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The foregoing and other features, and advantages ofthe disclosure are apparent from the following detailed descriptiontaken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of an example of a gas furnace system;

FIG. 2 is a perspective view of a blower assembly of the gas furnacesystem according to an embodiment;

FIG. 3 is a perspective view of a fan wheel of the blower assemblyaccording to an embodiment;

FIG. 4 is an exploded perspective view of a fan wheel of FIG. 3according to an embodiment;

FIG. 5 is another exploded perspective view of a fan wheel of FIG. 3according to an embodiment;

FIG. 6 is a side view of a fan wheel of FIG. 3 according to anembodiment;

FIG. 7 is an end view of a portion of the fan wheel of FIG. 3 accordingto an embodiment;

FIG. 8 is a cross-sectional view of a portion of the fan wheel of FIG. 3according to an embodiment;

FIG. 9 is a perspective view of a portion of the fan wheel of FIG. 3according to an embodiment;

FIG. 10 is a cross-sectional view of a portion of the fan wheel of FIG.3 after a welding operation according to an embodiment;

FIG. 11 is a perspective view of a portion of the fan wheel and anesting fixture according to an embodiment;

FIG. 11A is a detailed perspective view of the nesting fixture of FIG.11 according to an embodiment;

FIG. 12 is a perspective view of a support ring of the fan wheelaccording to an embodiment; and

FIG. 13 is a perspective view of a fan assembly including the supportring of FIG. 12 according to an embodiment.

DETAILED DESCRIPTION

With reference to FIG. 1, an example of a gas furnace system isillustrated generally at 20. The gas furnace system 20 includes ahousing 22 having a plurality of exterior walls 24, 26, 28 and aninterior dividing wall 30 that forms a heat exchange portion 32 and ablower portion 34. Heat exchange portion 32 includes a component supportwall 36 which, as will be discussed more fully below, provides structurefor mounting various components of the gas furnace system 20. Housing 22is also shown to include an access panel 38 that provides access to theblower portion 34 and another access panel (not shown) that providesaccess to heat exchange portion 32.

The gas furnace system 20 additionally includes a burner assembly 40mounted to component support wall 36. Burner assembly 40 includes aburner box 42 and a gas valve 44. Burner assembly 40 combusts a fuel, inthe form of gas, to generate heat used to condition a comfort zone suchas living spaces, work spaces and the like. As will be discussed morefully below, products of combustion or exhaust gases generated by theburning of the fuel are expelled to ambient. In the embodiment shown,burner assembly 40 is operatively connected to a primary heat exchanger46 arranged within heat exchange portion 32. Primary heat exchanger 46is operatively coupled to a condensing heat exchanger 48. Condensingheat exchanger 48 includes a plurality of heat exchange members 50. Withthis arrangement, a blower assembly 52 arranged within the blowerportion 34 draws in air from a space to be heated. The air is guidedover primary heat exchanger 46 and heat exchange members 50 ofcondensing heat exchanger 48 such that the air is heated before beingre-introduced into the space.

During operation of the gas furnace system 20, moisture from theproducts of combustion condenses condensing heat exchanger 48. Thismoisture collected and passed on to an external drain (not shown). Themoisture is guided to a condensate collector box 54. Condensatecollector box 54 is secured to component support wall 36. The moistureis collected in condensate collector box 54 and passed to a condensatetrap 56 and on to the external drain. Gas furnace system 20 furtherincludes an inducer fan assembly 58 mounted to condensate collector box54. Inducer fan assembly 58 creates an air flow that establishes a draftwhich draws the products of combustion from burner box 42 throughprimary heat exchanger 46 and heat exchange members 50 of the condensingheat exchanger 48. More specifically, inducer fan assembly 58 produces apressure rise and flow rate to achieve a desired combustion performancewhile overcoming flow losses within gas furnace system 20. The productsof combustion are then exhausted through a flue vent 60.

With reference now to FIG. 2, the blower assembly 52 is illustrated inmore detail. Although the blower assembly 52 is illustrated anddescribed herein with reference to a furnace, it should be understoodthat the blower assembly 52 may be used in other suitable applications,such as in an air handling unit of an HVAC and/or refrigeration systemfor example. The blower assembly 52 includes a fan wheel 62 positionedwithin a blower housing 64. The blower housing 64 has an outer wall 66having a scroll-shaped length that extends from a first end edge 68 toan opposite second end edge 70. The first end edge 68 the second endedge 70 define opposite sides of an outlet opening 72 of the blowerhousing 64. Although the outlet opening 72 is illustrated as beinggenerally rectangular in shape, embodiments where the outlet opening 72is another shape are also contemplated herein. The blower housing 64additionally includes a first sidewall 74 and a second sidewall 76. Asseen in the FIG., portions of the peripheries of the first sidewall 74and the second sidewall 76 are connected to opposite sides of the outerwall 66. The first sidewall 74 has a first straight edge portion 78extending between the outer wall first end edge 68 and the outer wallsecond end edge 70 and the second sidewall 76 similarly has a secondstraight edge portion 80 extending between the outer wall first end edge68 and the outer wall second end edge 70. The first sidewall 74 includesa first aperture 82 and the second sidewall includes a second aperture(not shown).

With reference now to FIGS. 3-10, the fan wheel 62 is illustrated inmore detail. The fan wheel 62 is typically formed as an assembly ofthree primary components: a first wheel portion 100, a second wheelportion 102, and a support ring 104 located centrally between the firstwheel portion 100 and the second wheel portion 102. When the fan wheel62 is incorporated into a blower assembly 52 of a furnace system, suchas system 20 of FIG. 1, both the first wheel portion 100 and the secondwheel portion 102 are configured to provide air to an adjacent componentand are associated with a single plenum. The first wheel portion 100includes a shroud 106 and a first plurality of impeller blades 108spaced about a periphery of the shroud 106 and connected thereto at afirst end 110. The second wheel portion 96 similarly includes a shroud112 and a second plurality of impeller blades 114 arranged about aperiphery of the shroud 112 and connected thereto at a first end 116. Inan embodiment, one or both of the first plurality and the secondplurality of impeller blades 108, 114 are configured as backward curvedimpeller blades. However, embodiments where one or both of the firstplurality and second plurality of impeller blades 108, 114 have aforward curved configuration, or another configuration are alsocontemplated herein.

In an embodiment, the first wheel portion 100 is dissimilar from thesecond wheel portion 102 such that the fan wheel 62 has an asymmetricalconfiguration about a plane oriented parallel to an intersecting thesupport ring 104. Examples of a fan blower 62 having an asymmetricalconfiguration are disclosed in U.S. Provisional Application Ser. No.62/409,669 filed on Oct. 18, 2016, the entire contents of which areincorporated herein by reference. Alternatively, embodiments where thefirst wheel portion 100 and the second wheel portion 102 have asymmetric configuration are also considered within the scope of thedisclosure.

The support ring 104 is configured to connect to the second end 118, 120of both the first plurality of impeller blades 108 and the secondplurality of impeller blades 114, respectively. Accordingly, the supportring 104 forms a barrier separating the blades 108, 114 of the firstwheel portion 100 and a second wheel portion 102. As a result, the firstplurality of impeller blades 108 is axially spaced from the secondplurality of impeller blades 114. The support ring 104 has a generallyplanar configuration. In an embodiment, the support ring 104 has acentral opening 122 and an inner diameter of the central opening 122 isslightly greater than or equal to the inner diameter defined by an inneredge 124, 126 of at least one of the first plurality and the secondplurality of impeller blades 108, 114, respectively. Similarly, an outerdiameter of the support ring 104 is generally equal to the outerdiameter of the fan wheel 62 which may be defined by an outer edge 128,129 of at least one of the first plurality and the second plurality ofimpeller blades 108, 114.

A circular connector 130, 132 (see FIGS. 4 and 5) couples the inner edge124, 126 of the second end 118, 120 of each the first plurality ofimpeller blades 108 and the second plurality of impeller blades 114,respectively. In the illustrated, non-limiting embodiment, a central hub134 for mounting the fan wheel 62 to a drive shaft 136 for rotationabout an axis X is coupled to the connector 130 of the first wheelportion 110. As best shown in FIG. 6, the central hub 134 and theconnector 130 may be integrally formed, or alternatively, may beconnected, such as via fasteners or another suitable connectionmechanism. Because the central hub 134 is associated with the connector130, a diameter of the central hub 134 is generally complementary to orreceivable within the hollow interior of the support ring. Although thefirst wheel portion 100 is illustrated as incorporating the central hub134, embodiments where the second wheel portion 102 alternativelyincludes the hub 134 are also within the scope of the disclosure.

One or more of the first wheel portion 100, second wheel portion 102,and support ring 104, is formed from a polymer or plastic materialhaving a suitable fire rating. Examples of suitable materials include,but are not limited to a glass fiber reinforced, flame retardant,Polyamide 6, such as Schulamid® 6 GBF 3015 FR 4 for example, Polyamide66, such as Ultramid® 66 H2 G/35-V0KB1 BK3324 for example, and a Nylon6/6, such as RTP 299 X 141130 B for example. In an embodiment, thematerial selected for at least one of the first wheel portion 100,second wheel portion 102, and support ring 104 will satisfy the testingstandards of the UL certification UL94 V-0, 5VA. The materials of thefirst wheel portion 100, second wheel portion 102, and support ring 104,may be the same, or alternatively, may be different. Further, in anembodiment, the support ring 104 may be formed from a material having areduced amount of glass fiber compared to at least one of the firstwheel portion 100 second wheel portion 102.

The support ring 104 includes a plurality of blade receiving areasspaced about the periphery thereof. As shown, a first plurality of bladereceiving areas 140 formed in a first surface 142 of the support ringare adapted to receive the second ends 118 of the first plurality ofimpeller blades 108, respectively. Similarly, a second plurality ofblade receiving areas 144 formed in a second, opposite surface 146 ofthe support ring 104 are adapted to receive the second ends 120 of thesecond plurality of impeller blades 114, respectively. As shown, thefirst plurality of blade receiving areas 140 is substantially alignedwith the second plurality of blade receiving areas 144 (see FIGS. 8 and10). However, embodiments, where the first plurality of blade receivingareas 140 are offset from the second plurality of blade receiving areas144, as shown in FIG. 11, are also contemplated herein.

In an embodiment, best shown in FIGS. 8-10, each of the blade receivingareas 140, 144 includes a land 150 defined by a first groove 152 locatedadjacent a first side of the land 150, and a second groove 154positioned adjacent a second side of the land. A second end 118, 120 ofa corresponding impeller blade 108, 114 is positioned in direct contactwith the surface of the land 150. The second end 118, 120 of thecorresponding impeller blade 108, 114 and the land 150 are attached,such as via a welding operation for example, to integrally form the end118, 120 of the impeller blade 108, 114 with the support ring 104. Whenthe land 150 and/or the blades 108, 114 are heated, a force is appliedto the blade 108, 114 such that the end 118, 120 of the blade 108, 114displaces all or a portion of the material of the land 150. As a result,during the process of attaching of the blades 108, 114 to the supportring 104, one or both of the first and second grooves 152, 154positioned adjacent each land 150 may fill at least partially withoverflow material generated by affixing the blade end 118, 120 to theland 150 of the support ring 104.

During a welding operation, a nesting fixture 160, best shown in FIGS.11 and 11A, is received within the hollow interior of the first wheelportion 100 and/or the second wheel portion 102. One or more grooves 162may be formed in the outer periphery 164 of the nesting fixture 160. Thegrooves 162 are sized to receive the inner end 124, 126 of the pluralityof impeller blades 108, 114 of a corresponding wheel portion 100, 102.The nesting fixture 160 maintains an orientation of the blades 108, 114as heat is applied thereto and the blades 108, 114 are forced intocontact with blade receiving areas 140, 144 of the support ring 104. Inan embodiment, the nesting fixture 160 includes one or more indexingfeatures 166 that align with a corresponding notch or cavity formed inthe support ring 104. Inclusion of these indexing features 166 ensuresthat the nesting fixture 160 is always arranged in the same orientationrelative to the support ring 104 during a welding operation.

With reference now to FIGS. 12 and 13, in another embodiment, the bladereceiving areas 140, 144 include pockets 170 formed in the first and/orsecond surface 142, 146 of the support ring 104. The pockets 170 may beformed by one or more sidewalls 172 that extend from a surface 142, 146of the support ring 104 and that define an opening 174 there between.The opening 174 is generally complementary, i.e. has a similar size andshape to the second end 118, 120 of the impeller blade 108, 114 beingreceived therein. In embodiments where the blade receiving areas 140,144 include such pockets 170, the blades 108, 114 are coupled to thesupport ring 104 mechanically, and no further attachment process, suchas a welding operation for example, is required to couple the wheelportions 100, 102 to the support ring 104.

When the first wheel portion 100 and the second wheel portion 102 areattached to the support ring 104, the circular connector 130, 132 ofboth the first and second wheel portions 100, 102 directly about oneanother, as best shown in FIG. 9. During the assembly of the first andsecond wheel portions 100, 102 to the support ring 104, the circularconnectors 130, 132 may similarly be coupled to one another. In anembodiment, a welding operation is used to attach the circularconnectors 130, 132. Heat may be applied at the interface between thecircular connectors 130, 132, each of which similarly includes a raisedsurface 180 and a first and second groove 182, 184 disposed on opposingsides of the raised surface 180. With the applied heat, the raisedsurfaces 180 in melt together to integrally form the circular connectors130, 132. The melted material may additionally flow from the raisedsurfaces 180 into one or both of the first and second grooves 182, 184.In an embodiment, a welding operation, such as the application of heatfor example, may be used to couple the circular connectors 130, 132,regardless of whether the wheel portions 100, 102 are welded,mechanically connected using fasteners or molded in snap features, orover-molded to the support ring 104.

The fan wheel 62 as illustrated and described herein has an improvedefficiency compared to conventional fan wheels 62. As a result, a motorhaving a decreased horsepower can be used to satisfy regulatory furnaceefficiency requirements. Further, the use of plastic molding and themanufacturing processes associated therewith result in reducedclearances and refined blade aerodynamic profiles which may increase theaerodynamic performance of the fan wheel.

The blower assembly 52 illustrated and described herein has an improvedefficiency compared to conventional blower assemblies. In addition, theblower assembly 52 may be adapted for use in the blower portion 34 ofexisting furnaces 20 without requiring modification of the cabinet orhousing.

Embodiment 1: A method of assembling a fan wheel comprising: forming afirst wheel portion including a first plurality of impeller blades and afirst connector; forming a second wheel portion including a secondplurality of impeller blades and a second connector; affixing an end ofeach of the first plurality of impeller blades to a first surface of asupport ring such that the first connector is affixed to the secondconnector; and affixing an end of each of the second plurality ofimpeller blades to a second surface of a support ring.

Embodiment 2: The method of embodiment 1, wherein the first wheelportion is formed separately from the second wheel portion.

Embodiment 3: The method of embodiment 1, wherein affixing the end ofthe first plurality of impeller blades to the first surface of a supportring includes positioning the ends of the first plurality of impellerblades at a plurality of blade receiving areas of the first surface ofthe support ring.

Embodiment 4: The method of embodiment 3, wherein positioning the endsof the first plurality of impeller blades at a plurality of bladereceiving areas of the first surface includes positioning the ends ofthe first plurality of impeller blades within a plurality of pocketsformed in the first surface of the support ring.

Embodiment 5: The method of embodiment 4, wherein each of the pocketsfurther comprises a first sidewall, a second sidewall, and an openingdefined between the first sidewall and the second sidewall, andpositioning the ends of the first plurality of impeller blades withinthe plurality of pockets further comprises installing the ends of thefirst plurality of impeller blades within the openings of the pluralityof pockets.

Embodiment 6: The method of embodiment 3, wherein each of the pluralityof blade receiving areas includes a land and at least one grooveadjacent the land, and positioning the ends of the first plurality ofimpeller blades at a plurality of blade receiving areas of the firstsurface includes further comprises positioning the ends of the firstplurality of impeller blades in direct contact with the plurality oflands.

Embodiment 7: The method of embodiment 6, wherein affixing an end ofeach of the first plurality of impeller blades to a first surface of asupport ring further comprises welding the ends to the plurality ofblade receiving areas of the first surface of the support ring.

Embodiment 8: The method of embodiment 7, wherein welding the ends tothe plurality of blade receiving areas of the first surface of thesupport ring further comprises welding the ends of the first pluralityof impeller blades to the plurality of lands.

Embodiment 9: The method of embodiment 8, wherein welding the ends ofthe first plurality of impeller blades to the plurality of landsdisplaces a portion of material of the lands into the at least onegroove.

Embodiment 10: The method of embodiment 1, wherein coupling the firstconnector and the second connector includes welding the first connectorto the second connector.

Embodiment 11: The method of embodiment 1, wherein at least one of thefirst wheel portion and the second wheel portion is formed via a plasticmolding process.

Embodiment 12: A fan wheel for use in a blower assembly, comprising: afirst wheel portion including a first plurality of impeller blades; asecond wheel portion including a second plurality of impeller blades; asupport disk positioned near a center of the fan wheel, between thefirst wheel portion and the second wheel portion, wherein the supportdisk couples the first wheel portion to the second wheel portion and atleast one of the first wheel portion, the second wheel portion, and thesupport disk is formed from a plastic material.

Embodiment 13: The fan wheel of embodiment 12, wherein the first wheelportion, the second wheel portion, and the support ring are formedseparately.

Embodiment 14: The fan wheel of embodiment 12, wherein the fan wheelincludes a first plurality of blade receiving areas formed in a firstsurface and the fan wheel includes a second plurality of blade receivingareas formed in a second, opposite surface.

Embodiment 15: The fan wheel of embodiment 14, wherein the firstplurality of impeller blades are welded to the first plurality of bladereceiving areas.

Embodiment 16: The fan wheel of embodiment 14, wherein the firstplurality of impeller blades are mechanically coupled to the firstplurality of blade receiving areas.

Embodiment 17: The fan wheel of embodiment 16, wherein the firstplurality of blade receiving areas include a plurality of pocketsincluding openings complementary to the first plurality of impellerblades.

Embodiment 18: The fan wheel of embodiment 14, wherein the first wheelportion further comprises a first connector and the second wheel portionfurther comprises a second connector and the first connector is coupledto the second connector.

Embodiment 19: The fan wheel of embodiment 14, wherein the firstconnector is welded to the second connector.

While the disclosure has been described in detail in connection withonly a limited number of embodiments, it should be readily understoodthat the disclosure is not limited to such disclosed embodiments.Rather, the disclosure can be modified to incorporate any number ofvariations, alterations, substitutions or equivalent arrangements notheretofore described, but which are commensurate with the spirit andscope of the disclosure. Additionally, while various embodiments of thedisclosure have been described, it is to be understood that aspects ofthe disclosure may include only some of the described embodiments.Accordingly, the disclosure is not to be seen as limited by theforegoing description, but is only limited by the scope of the appendedclaims.

What is claimed is:
 1. A fan wheel for use in a blower assembly,comprising: a first wheel portion including a first plurality ofimpeller blades; a second wheel portion including a second plurality ofimpeller blades; a support disk positioned near a center of the fanwheel, between the first wheel portion and the second wheel portion,wherein the support disk couples the first wheel portion to the secondwheel portion and at least one of the first wheel portion, the secondwheel portion, and the support disk is formed from a plastic material,wherein a first surface of the support disk includes a first pluralityof blade receiving areas, each of the first plurality of blade receivingareas including a planar land defined between a first groove and asecond groove.
 2. The fan wheel of claim 1, wherein the first wheelportion, the second wheel portion, and the support ring are formedseparately.
 3. The fan wheel of claim 1, wherein the support diskincludes a second plurality of blade receiving areas formed in a second,opposite surface.
 4. The fan wheel of claim 3, wherein the firstplurality of impeller blades are welded to the first plurality of bladereceiving areas.
 5. The fan wheel of claim 3, wherein the firstplurality of impeller blades are mechanically coupled to the firstplurality of blade receiving areas.
 6. The fan wheel of claim 3, whereinthe first wheel portion further comprises a first connector and thesecond wheel portion further comprises a second connector and the firstconnector is coupled to the second connector.
 7. The fan wheel of claim6, wherein the first connector is welded to the second connector.